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Header Install on '05 ZX4 SE

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6.5K views 24 replies 11 participants last post by  gonefhsn  
#1 · (Edited)
I couldn't decide if this thread belonged in here or the Ford Focus Showroom, so I chose this one. If it's wrong, I'm sure a mod will move it.

I finally was able to install my F2 Header today with the help of Josh (gonefhsn, rep to follow). Wasn't too bad overall, but here's some things to keep in mind for those that want to install a header on a 2.0L Dtec.

1) I think F2 makes these headers when they get ordered because the holes on the flange were a bit snug. We got it to work, though.

2) The space for the header is a really tight fit, so pulling the old one out was a PITA. Let's just say that it was a good thing the motor mounts have a little bit of give to them as it was just enough to get the mani-cat out.

3) When doing the Mechanical Fix for the CEL, keep in mind that, due to space issues, I had to plug the bottom hole and place the number 1 O2 sensor in the top hole and the number 2 O2 sensor in the middle. It worked for me as I have yet to get the CEL.

4) This is just a bonus tip regarding the manifold nuts, spray them with some WD-40 to get them to break free easier. I had three of the studs come out with the nuts.

Everything else went pretty well. The flex lined up perfectly to my Magnaflow exhaust. I love this mod and am so glad that I did it. [headbang] I didn't take a whole lot of pics but here is what I have, nonetheless:

The Before Header Sound Clip


The Work Space
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The Void
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Out With The Old
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In With The New
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Header Installed
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The After Header Sound Clip


I know some people used some high heat silicone to fill in the reso tip of the Magnaflow system, but I did not because it sounds just awesome to me. I didn't hear any "tinny" sound or anything.
 
#9 ·
Cjohn , car sounds good .

Few quick questions , Did you go in from the top or the bottom? I still have my F2 header in the box, just waiting on warmer weather and it to stop raining around here so much and I'll be getting mine put in .
 
#15 ·
You will have to go in from the top. You will not have enough room to go through the bottom.

did you have to adust your tune when you histalled the header.
I don't have a flasher yet so I'm still running on the stock tune. I did disconnect the negative battery terminal to reset the ECU, though.

what about a check engine light
Click on the mechanical fix link I inserted in the original post, but I still have no CEL after doing the fix.
 
#17 ·
i'm sure i'll get flamed for this one, but is it just me or does the stock exhaust manifold not look too restrictive. it is a 4-1 header if you think about it, and the stock flex pipe looks pretty big. the cat is what just makes it restrictive. if you have a cat-back that deletes the secondary cat (Ford Racing), then you have less restriction.
 
#18 ·
aTm [:) said:
[:)][:)][:)][:)][:)];2715788]i'm sure i'll get flamed for this one, but is it just me or does the stock exhaust manifold not look too restrictive. it is a 4-1 header if you think about it, and the stock flex pipe looks pretty big. the cat is what just makes it restrictive. if you have a cat-back that deletes the secondary cat (Ford Racing), then you have less restriction.
The stock mani-cat is not THAT restrictive; however, the F2 header eliminates the cat and has bigger tubing so combine that with a bigger exhaust and a high flow cat, you reduce restriction a whole lot more and your engine breaths better.

*edit* I have no idea why the second half of your screen name got smilied out in the quote. [dunno]
 
#19 ·
Posted via FF Mobile

I guess the best way to see how much restriction is caused by the exhaust manifold is too see a header dyno with at least intake, header, and exhaust. the reason I ask is because I don't know if I want to add a header on my car due to emissions. I do want to add stage 1 cams and I think all that is needed would be an intake and exhaust.
 
#24 ·
duratecs love to breathe, itll be so much sweeter with a tune! mine was ok after the header but once i got it tuned it was complete lol grats!